Panel for inclusion in a unit to be installed in a building opening



N. E. SMITH March 14, 1967 PANEL FOR INCLUSION IN A UNIT TO BE INSTALLED IN A BUILDING OPENING 2 Sheets-Sheet 1 Filed March 25, 1965 Fig.5

INVENTOR NORMAN EARLE SMITH ATTORNEY N. E. SMITH 3,308,593 PANEL FOR INCLUSION IN A UNIT TO BE INSTALLED IN A BUILDING OPENING 2 Sheets-Sheet 2 March 14, 1967 Filed March 25, 1965 O M h I 1 INVENTOR NORMAN EARLE SMITH 7 w\ m\ uw United States Patent 3,308,593 PANEL FOR INCLUSION IN A UNIT TO BE INSTALLED IN A BUILDING OPENING Norman Earle Smith, Miami Beach, Fla., assignor to Crossly Window Corp., Miami, Fla. Filed Mar. 25, 1965, Ser. No. 442,674 Claims. (Cl. 52-456) This invention relates to a panel for inclusion in a unit adapted to be installed in a building opening, and, more particularly, to a panel including two superposed and spaced panes with a decorative assembly housed in and retained in fixed relation within an insulating space between the panes.

As is perhaps well known, certain architectural plans call for windows which include mullions; however, the cost of mullion windows is considerably more than the cost of plain windows, and, in addition, once installed, are considerably more difiicult to clean, it being quite troublesome to clean the relatively small and conventional panes along the marginal areas adjacent the mullion members. To this end, windows have been manufactured, sold and patented which are characterized by a single pane with a mullion construction overlying the pane and removably fastened to the peripheral frame of the window unit. Thus, the mullion construction may be removed from the frame and the surfaces of the single pane cleaned in one continuous cleaning operation.

Also, in the past, insulated panels have been manufactured which are of the type generally characterized by spaced panes of glass with a peripheral spacer means therebetween to provide structure to enclose an insulation space between the panes. In the present invention an insulated type panel is provided which includes a first and a second pane with a peripheral spacer means therebetween as well as a decorative grillwork, such as a mullion construction, in the insulation space or pocket, and, further, the instant invention includes means connecting the decorative work and the peripheral spacerframe to maintain the alignment of the members of the decorative work prior to installation of the panel in a window unit and prior to, during and after the times that the unit is installed in a building opening.

Because the decorative construction is housed within the insulation space, each side of a panel constructed in accordance with this invention may be cleaned in one continuous cleaning operation without disturbing or, indeed, contacting a mullion construction included in the panel. Further, by reason of the mullion construction being r tained in a fixed position in the inner pocket of the panel, a panel constructed in accordance with this invention may be stored and transported to a site for assembly in a window unit and, thereafter, the unit transported to a job site, all without misalignment of the mullion construction in the pocket. It will be readily appreciated that this is an important feature of the instant invention upon consideration of the fact that often windows of buildings include an upper and lower sash and that, if the vertical members of the mullions of the lower sash are not correctly aligned with those of the upper member, an incongruous appearing window is the result, which incongruity cannot be corrected except upon a time-consuming and expensive total dismantling and reconstruction of an installed window unit and panel. Also, the effects of mullion misalignment are quite visible and undesirable in single sash units; however, the effects are exaggerated and totally unacceptable when such occurs in a double sash window.

Thus, it is a main object of this invention to provide a generally planiform panel for a window unit which includes a first and a second pane in adjacent, but spacedapart relation, and which sandwiches therebetween, in the insulation space thus formed, a frame including a decorative grill held in a fixed position relative to the frame.

It is a further object of this invention to provide an insulated panel or parallelepipedal configuration formed of two panes maintained in spaced apart relation by a spacer frame, with the side surfaces of the panel being sealed against moisture entrance thereinto and which includes a decorative grillwork between the panes, the said panel being adapted to be readily installed in a carrier unit.

It is also an object of this invention to provide a frame and connected mullion construction for inclusion between two spaced panes in surface-abutting relation to the frame and mullion construction.

It is a general object of this invention to provide a panel including two panes separated by a frame and connected mullion structure between the panes which is of relatively inexpensive construction yet sturdy and durable and otherwise well adapted for use in combination with a unit to be installed in a building opening.

In accordance with these and other objects which will become apparent hereinafter, the instant invention will now be described with reference to the accompanying drawings illustrating a preferred embodiment thereof.

In the drawings:

FIG. 1 is an exploded perspective view of the panel before being bonded together, said figure illustrating the relatilve arrangement of the constituent elements of thepane FIG. 2 is a partially exploded perspective view and showing the arrangement of the frame and mullions or decorative members in overlying relation to a lower pane;

FIG. 3 is a side elevation view of the assembled elements of FIG. 1;

FIG. 4 is an enlarged perspective view of that portion of FIG. 3 with the arrow 44 therearound;

FIG. 5 is a perspective view of a completed panel in association with a window unit sized to receive it;

FIG. 6 is an enlarged cross-sectional view taken along the plane of the line 6-6 of FIG. 5 and looking in the direction of the arrows;

FIG. 7 is a cross-sectional view of FIG. 6 taken along the various planes indicated by the line 77 of FIG. 6 and looking in the direction of the arrows;

FIG. 8 is a cross-sectional view of that portion of FIG. 6 indicated by the arrow 88 therearound;

FIG. 9 is an exploded perspective view, partly in cross section, and illustrating connecting means for the ends of the mullions to the mullions;

FIG. 10A is an exploded perspective view illustrating modified connecting means of the frame and a mullion member of a modified cross-sectional area relative to that of the cross-sectional area of the mullion of FIG. 9; and

FIG. 10B is a partial view, partly in cross section, similar to FIG. 8 and illustrating a modified or alternative means for connecting the mullion to the frame.

Referring more particularly to the drawings, wherein like reference characters designate like or corresponding parts throughout the different views, and, initially, referring briefly to FIG. 5, the numeral 11 of FIG. 5 generally designates a window frame of companionate size with the panel, generally designated by the numeral 12, to seat and support it in bridging relation. As best seen in FIG. 1, the panel includes a first and a second congruent pane designated 14 and 16 respectively, in superposed relation, and a spacer frame 18 adapted to be sandwiched between the panes, as indicated in FIG. 3. The members of the frame 20, 22, 24, and 26 are generally parallel to the side edges 28, 30, 32, and 34 of the first pane 14 and, also, parallel to the corresponding side surfaces 28', 30', 32', and 34' of the second pane. However, the size of the frame is foreshortened relative to that of the congruent panes, i.e., of reduced dimensions such that when opposite faces 36 and 38 of the frame are in abutting engagement with the margins of the confronting surfaces 42 and 44 of the panes, a verge between the panels or border space indicated by the numeral 46 is thus defined The border space, which is designated 46, as seen clearly in FIG. 3, extends around the periphery of the assembly of the panes and frame for purposes to be described hereinafter, and the space 46 is bounded by the panes, a lane through the brink 48 and 48' of the panes and the outwardly-extending surfaces of the frame. When the panes are in sandwiched relation, in addition to the border space, an inner isolated pocket is defined between the panes This inner pocket is divided into discrete compartments by means of mullion means, or decorative means, generally designated 50, which span a portion of the pocket. Preferably, the mullion means are suitably patterned in decorative, architecturally appealing fashion and are formed of a plurality of members, such as 52, 54 and 56 and 57 and 58 of FIG. 6. Referring to FIGS. 8-1 OB, means generally designated 59 are provided which connect the ends of the mullions to the frame. As shown, the means of FIGS. 9 and 10A are similar in that they are in the form of a staple 60, that is, a U-shaped metal loop, both ends of which are passed through the frame and into the pocket to embrace the end of the mullion between-the legs or prongs 62 and 64, either exteriorly or interiorly of the mullion as shown in FIGS. 9 and 10A respectively. Alternatively, as indicated in FIG. 10B, the means 59 to connect the ends of the mullion members to the spacer frame 18 may comprise spaced protuberances or dimples such as 66 and 66' to confine the mullion therebetween;

Reverting to the spacer frame 18 and referring to FIGS. 7. and 10A, inter alia, the members 20, 22, 24 and 26 are preferably in roll form or extruded metallic material of cylindrical character with smooth, parallel, pane-abutting sides generally designated 68 and 70 and including an outer peripheral bezel portion 71 extending into the border space 46 which, as a result of the extension, is generally U-shaped in cross section. The frame also includes a bottom wall 88, integral-with side walls 68 and 70. As seen in FIG. 6, interiorly carried juncture brackets, 72, 74, 76 and 78 are provided in wedge-type relation in the ends of the members to accommodate assembly of the frame; and, with continued reference to FIG. 6, the interior chambers of the members of the frame are packed with an adsorbent material having-many fine pores, preferably in granular form so as to be substantially flowa-ble, such as silica gel.

Reverting again, and this time to FIGS. 9 and 10A, it is seen that the mullion members, such as that designated by the numerals 57 and 57, are of a uniform, symmetrical, and preferably ogee type cross section, either with or without the re-entrant base portion 82 of FIG. 10A. As is apparent. from these figures, the staple legs 62 and 64, upon piercing and passing through the frame so as to extend into the inner pocket, form a bite to grip the apex 84 of the ogee of the mullion of FIG. 9, or to be received in the re-entrant portion 82 of the mullion 57 of FIG. 10A, so that, in either event, the ends of the respective mullions are held in fixed relation within the pocket, viz-a-viz the pocket side surface 88 of the frame.

The assembly of the panel includes the erection of the silica gel-carrying frame members to define the spacer frame 18, and the connection of the mullion means 50 to the frame 18 by means of the connector means or protuberances into the pocket. The frame and connected mullions are positioned as a unit in overlying relation on one pane 14 and over this the second congruent pane 16 is positioned. The frame and panes are quite securely retained in position by the relative high-frictional component caused by the abutting smooth surfaces of the frame and the panes. Following this assembly, the border space is filled with a suitable cohesive bonding agent 4 92 which is applied by brush, spray or other suitable means to cause the panel parts to be sealed against the entry of moisture and to adhere together for positioning in a window unit as indicated in FIG. 5, the said panel of FIG. 5 being shown in parallelepipedal form.

Let it be known, that panels constructed'in accordance with this invention are, by reason of the aforesaid construction, sealed against the deleterious effects of moistureby means of the bonding agent in the border space or channel 46 and that the silica gel of the frame 18 acts to adsorb any moisture which may penetrate the panel and also any condensate which may form withinthe pocket of the panel.

While the instant invention has been shown anddescribed in what is conceived to be most practical and preferred embodiments, itis recognized that departures may be made therefrom within the scope of the invention, which is therefore not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent apparatus and articles.

What is claimed is: t v

1. In a panel structure for fitting within and closing a frame adapted to be set in a wall opening, first and second panes of regular geometrical contour, a spacer frame having a bottom wall and parallel spaced planar side walls extending outwardly from and integralwith the respective edges of said bottom wall, said spacer frame being interposed between said panes to space the panes and to define therewith a closed space, a mullion within said closed space and comprising at least one elongated muntin element having its ends abutting said bottom wall at points spaced therealong, and means projecting inwardly from said bottom wall in fixed relation therewith, at each point of contact of said muntin element with said bottom wall and in contact with laterally opposed surfaces of said muntin element, to maintain said mullion fixed with respect to said frame.

2. The panel of claim 1, said last-named means comprising a plurality of pairs of spaced protuberances extending inwardly from and fixed with the bottom wall of said frame, there being one said pair of protuberances' at each point of contact of a muntin element with the bottom wall of said frame, each said pair of protuberances being in contact with a respective one of two opposed laterally-spaced surfaces of the muntin element at that point.

3. The panel of claim 1, there being a plurality of pairs of longitudinally spaced holes in said bottom wall, one said pair at each said point, and a plurality of prongs, each said prong projecting through a hole of a respective one of said pairs, each prongs of a pair engaging a respective one of two laterally-spaced surfaces of the muntin element at that point.

4. The panel of claim 3, the outer periphery of said frame being set inwardly from the edges of said panes to define therewith a peripheral channel, each of said pair of prongs comprising the legs of a respective one of a plurality of staples each having its bight lying within said channel.

5. The panel of claim 4, and a cohesive bonding agent filling said channel in contact with said frame and the areas of said panes defining said channel, to embed therein the bights of said staples.

6. For assembly with a panel including two spaced panes, a planiform frame and mullion construction, said frame circumscribing a space to be closed at each end by the panes in sandwich relation, the frame faces on the'opposing sides of the frame which are presented tothe panes in assembly being smooth and in respective common planes transverse of the center line of the circumscribed space; a mullion pattern connected to theframe and spanning the circumscribed space, said mullion pattern comprising a plurality of interconnected members of symmetrical, ogee type cross section with the apex of the ogee being flat and coplanar with one of the frame faces and the base of the ogee including a base surface coplanar with the opposing face of the frame to divide the space into discrete compartments when the space is closed by the panes, and means to connect the mullion pattern to the confronting surfaces of the frame, said connecting means comprising a staple passed through the frame with the legs of the staple extending into the space and engaging opposite side surfaces of the apex of the mullion members.

7. A parallelepipedal panel, for inclusion in a unit adapted to be installed in a building opening, said panel comprising: (a) a first and second congruent planiform parallelogrammatical pane of glass in adjacent, spaced, superposed relation; (b) a spacer frame, including a first and a second opposing pair of connected parallel coplanar members, intermediate said panes, said frame being fores'hortened relative to the congruent panes so as to lie completely between the panes and define a peripheral border space; the members of said frame having smooth opposite faces presented to and in abutting engagement with the respective confronting surfaces of the panes to enclose a pocket between the panes, said opposite faces of the members on each side of the frame being substantially coplanar; the members of said frame being of tubular construction with cylindrical surfaces circumposing an elongated recess, the cross-sectional area of the members of the frame being of reduced thickness on the outwardly surface facing the border space to define a peripheral bezel in said space; moisture adsorbing means in the recess of the members; adjoining means carried by the members of the frame adjacent the ends of the respective members to interlock said members and to retain the adsorbing means in the recesses; a decorative grillwork in the pocket comprising a plurality of interconnected elongate mullions, the said grillwork abutting the frame at least at two spaced points; connector means on the frame adjacent the spaced points and extending into the pocket to engage the grill- Work to hold it within the frame in a predetermined position, said connector means comprising a pair of spaced protuberances in the pocket on each side of each of the said spaced points to engage a portion of the grillwork and hold it between the protuberances, and a set, sealing and bonding agent in the border space, the outwardly facing surface of the agent being in a plane generally perpendicular to that of the respective planes of the outer surfaces of the panel panes.

8. A panel as set forth in claim 7, wherein each of said protuberances comprises the leg of a staple passed through the frame and extending into the pocket with a leg of a staple being on each side of the spaced point to hold a portion of the grillwork therebetween from movement along the frame.

9. A panel as set forth in claim 8 wherein one of the said legs is on each side of each of the points and in holding engagement with opposing exterior sides of the grillwork.

10. A panel as set forth in claim 8 wherein the said legs are received in the said portion of the grillwork on each side of each of the spaced points.

References Cited by the Examiner UNITED STATES PATENTS 2,030,869 2/1936 Haven 52-616 2,132,217 10/1938 Neuendorf 52-455 X 3,077,643 2/1963 Horner 52616 X 3,099,865 8/1963 Burnett 52-456 X 3,105,274 10/1963 Armstrong 52616 X 3,226,903 1/1966 Lillethun 52-456 X FOREIGN PATENTS 730,103 5/1955 Great Britain.

HARRISON R. MOSELEY, Primary Examiner. KENNETH DOWNEY, Examiner, 

1. IN A PANEL STRUCTURE FOR FITTING WITHIN AND CLOSING A FRAME ADAPTED TO BE SET IN A WALL OPENING, FIRST AND SECOND PANES OF REGULAR GEOMETRICAL CONTOUR, A SPACER FRAME HAVING A BOTTOM WALL AND PARALLEL SPACED PLANAR SIDE WALLS EXTENDING OUTWARDLY FROM AND INTEGRAL WITH THE RESPECTIVE EDGES OF SAID BOTTOM WALL, SAID SPACER FRAME BEING INTERPOSED BETWEEN SAID PANES TO SPACE THE PANES AND TO DEFINE THEREWITH A CLOSED SPACE, A MULLION WITHIN SAID CLOSED SPACE AND COMPRISING AT LEAST ONE ELONGATED MUNTIN ELEMENT HAVING ITS ENDS ABUTTING SAID BOTTOM WALL AT POINTS SPACED THEREALONG, AND MEANS PROJECTING INWARDLY FROM SAID BOTTOM WALL IN FIXED RELATION THEREWITH, AT EACH POINT OF CONTACT OF SAID MUNTIN ELEMENT WITH SAID BOTTOM WALL AND IN CONTACT WITH LATERALLY OPPOSED SURFACES OF SAID MUNTIN ELEMENT, TO MAINTAIN SAID MULLION FIXED WITH RESPECT TO SAID FRAME. 